After sustaining a fingertip injury from a vertical belt sander, I required a splint to support bone healing following surgery. The medical braces provided were functionally effective but impractical for daily use; they were bulky, uncomfortable, and could not get wet due to fabric components.

With approval from my physician, I designed and fabricated a custom finger splint optimized for comfort, durability, and everyday wear. Using precise measurements of my finger (shown one year post-operation), I went through multiple design iterations and material tests to refine fit, flexibility, and performance. The splint incorporates a slight hyperextension angle to replicate the therapeutic positioning of standard medical braces.

The final design features a Voronoi lattice pattern to improve breathability and reduce material weight. PETG was selected for the primary structure to provide controlled flexibility without risk of fracture, while a TPU retention ring allows the splint to remain securely in place without added straps. Constructed entirely from plastic, the brace is fully waterproof and suitable for continuous daily use.

This project demonstrates iterative problem-solving, ergonomic customization, material selection, and the application of digital fabrication to real-world medical needs.

Date

Winter 2025

Software

Rhino 8, Grasshopper, Keyshot

Materials

PETG,TPU